Electrode connection and method therefor

ABSTRACT

In various examples, a component for a medical device is described. The component includes a conductor wire including a connection portion. An electrode is formed from a conductive tube. The conductive tube is compressed at least partially around the connection portion of the conductor wire to at least partially surround and couple to the connection portion.

CROSS REFERENCE TO RELATED APPLICATIONS

This application is a continuation of and claims the benefit of priorityunder 35 U.S.C. § 120 to Hestad et al., U.S. patent application Ser. No.16/669,887, now U.S. Pat. No. 11,241,184, filed on Oct. 31, 2019,entitled “ELECTRODE CONNECTION AND METHOD THEREFOR,” which claims thebenefit of priority to U.S. Provisional Application Ser. No. 62/757,787,filed on Nov. 9, 2018, entitled “ELECTRODE CONNECTION,” each of which isincorporated by reference herein in its entirety.

BACKGROUND

In lead or catheter construction, lead wires are connected to exposedelectrodes on the outside of the lead or catheter. The electrodes areexposed to the patient and the lead wires are most often insulated andcontained within the lead or catheter body. The lead wires create anelectrical pathway from the proximal connection to the exposedelectrodes. The lead wires are generally welded to the electrodes bymeans of laser or resistance welds. The welded areas are the sites ofhigh heat (needed to fuse the metals), which create a heat affected zone(HAZ) that degrades the mechanical properties of the wires. In flexibleleads, during normal use, the wire in the HAZ can bend and prematurelybreak, thereby potentially disrupting the electrical connection to theelectrode. The problem also exists in pad and cuff style electrodes.

OVERVIEW

This overview is intended to provide an overview of subject matter ofthe present patent document. It is not intended to provide an exclusiveor exhaustive explanation of the invention. The detailed description isincluded to provide further information about the present patentdocument.

The present inventors have recognized, among other things, that thepresent subject matter can be used in a device to connect a conductorwire to an electrode. Such a device includes, but is not limited to, amedical device. In various examples, the present subject matter isadvantageous in that it provides for a connection between the conductorwire and the electrode in a manner that can inhibit premature breakageof the conductor wire or breakage of the conductor wire from theelectrode. In some examples, the present subject matter inhibitsbreakage of the conductor wire and/or the connection between theconductor wire and the electrode within a heat affected zone (HAZ). Tobetter illustrate the devices described herein, a non-limiting list ofexamples is provided here:

Example 1 can include subject matter that can include a component for amedical device. The component includes a conductor wire including aconnection portion. An electrode is formed from a conductive tube,wherein the conductive tube is compressed at least partially around theconnection portion of the conductor wire to at least partially surroundand couple to the connection portion.

In Example 2, the subject matter of Example 1 is optionally configuredsuch that the connection portion of the conductor wire is disposedproximate a distal end of the conductor wire.

In Example 3, the subject matter of Example 1 or 2 is optionallyconfigured such that the connection portion is welded to the electrode.

In Example 4, the subject matter of Example 3 is optionally configuredsuch that the connection portion is laser welded to the electrode.

In Example 5, the subject matter of Example 3 is optionally configuredsuch that the connection portion is resistance welded to the electrode.

In Example 6, the subject matter of any one of Examples 1-5 isoptionally configured such that the conductive tube is compressed suchthat the electrode formed is substantially U-shaped.

In Example 7, the subject matter of any one of Examples 1-5 isoptionally configured such that the conductive tube is compressed suchthat the electrode formed is substantially T-shaped.

In Example 8, the subject matter of any one of Examples 1-7 isoptionally configured such that the medical device includes an elongatelead, wherein the electrode is disposed within the lead with at least anelectrode surface being exposed to an exterior of the lead.

In Example 9, the subject matter of any one of Examples 1-7 isoptionally configured such that the medical device includes an elongatecatheter, wherein the electrode is disposed within the catheter with atleast an electrode surface being exposed to an exterior of the catheter.

In Example 10, the subject matter of any one of Examples 1-9 isoptionally configured such that the conductive tube is compressed intodirect contact with the conductor wire.

In Example 11, the subject matter of any one of Examples 1-10 optionallyincludes a coupling tube, wherein the conductive tube is compressed intodirect contact with the coupling tube. The conductor wire is at leastpartially disposed within the coupling tube.

In Example 12, the subject matter of Example 11 is optionally configuredsuch that the conductor wire is coupled to the coupling tube.

In Example 13, the subject matter of Example 11 or 12 is optionallyconfigured such that the conductor wire is welded to the coupling tube.

In Example 14, the subject matter of any one of Examples 1-13 isoptionally configured such that the conductive tube includes an innersurface facing inwardly toward an axis of the conductive tube and anouter surface facing outwardly away from the axis of the conductivetube. The connection portion of the conductor wire is coupled to a firstportion of the inner surface, wherein the electrode includes theconductive tube collapsed such that at least the first portion of theinner surface and the connection portion of the conductor wire contactsat least a second portion of the inner surface to substantially sandwichthe connection portion of the conductor wire between the first portionof the inner surface and the second portion of the inner surface.

In Example 15, the subject matter of any one of Examples 1-14 isoptionally configured such that the conductive tube is compressed atleast partially around the connection portion of the conductor wire toconstrain motion of the connection portion of the conductor wirerelative to the conductive tube.

In Example 16, the subject matter of any one of Examples 1-15 isoptionally configured such that the electrode includes a rounded surfaceconfigured to contact and stimulate tissue of a patient.

In Example 17, the subject matter of any one of Examples 1-16 isoptionally configured such that the electrode includes a substantiallyflat surface configured to contact and stimulate tissue of a patient.

In Example 18, the subject matter of any one of Examples 1-17 isoptionally configured such that the conductive tube is folded at leastpartially around the connection portion of the conductor wire to formthe electrode.

In Example 19, the subject matter of Example 18 is optionally configuredsuch that the conductive tube is folded at least partially around acoupling tube within which the connection portion of the conductor wireis disposed to form the electrode.

Example 20 can include, or can optionally be combined with any one ofExamples 1-19 to include subject matter that can include a component fora medical device. The component includes a conductor wire including aconnection portion. An electrode is formed from a conductive tube,wherein the conductive tube includes an inner surface facing inwardlytoward an axis of the conductive tube and an outer surface facingoutwardly away from the axis of the conductive tube. The connectionportion of the conductor wire is coupled to a first portion of the innersurface, wherein the electrode includes the conductive tube collapsedsuch that at least the first portion of the inner surface and theconnection portion of the conductor wire contacts at least a secondportion of the inner surface to substantially sandwich the connectionportion of the conductor wire between the first portion of the innersurface and the second portion of the inner surface.

In Example 21, the subject matter of Example 20 is optionally configuredsuch that the conductive tube is collapsed such that the electrodeformed is substantially U-shaped.

In Example 22, the subject matter of Example 20 is optionally configuredsuch that the conductive tube is collapsed such that the electrodeformed is substantially T-shaped.

In Example 23, the subject matter of any one of Examples 20-22 isoptionally configured such that the connection portion is welded to theelectrode.

In Example 24, the subject matter of any one of Examples 20-23 isoptionally configured such that the connection portion is laser weldedto the electrode.

In Example 25, the subject matter of any one of Examples 20-23 isoptionally configured such that the connection portion is resistancewelded to the electrode.

In Example 26, the subject matter of any one of Examples 20-25 isoptionally configured such that the connection portion of the conductorwire is disposed proximate a distal end of the conductor wire.

In Example 27, the subject matter of any one of Examples 20-26 isoptionally configured such that the conductive tube is compressed intodirect contact with the conductor wire.

In Example 28, the subject matter of any one of Examples 20-27optionally includes a coupling tube, wherein the conductive tube iscompressed into direct contact with the coupling tube. The conductorwire is at least partially disposed within the coupling tube.

In Example 29, the subject matter of Example 28 is optionally configuredsuch that the conductor wire is coupled to the coupling tube.

In Example 30, the subject matter of Example 28 or 29 is optionallyconfigured such that the conductor wire is welded to the coupling tube.

In Example 31, the subject matter of any one of Examples 20-30 isoptionally configured such that the conductive tube is compressed atleast partially around the connection portion of the conductor wire toconstrain motion of the connection portion of the conductor wirerelative to the conductive tube.

In Example 32, the subject matter of any one of Examples 20-31 isoptionally configured such that the conductor wire includes a conductorcoil.

Example 33 can include, or can optionally be combined with any one ofExamples 1-32 to include subject matter that can include a method offorming a component for a medical device. The method includes placing aconnection portion of a conductor wire in contact with a conductivetube. An electrode is formed by compressing the conductive tube at leastpartially around the connection portion of the conductor wire to atleast partially surround and couple to the connection portion.

In Example 34, the subject matter of Example 33 is optionally configuredsuch that forming the electrode includes compressing the conductive tubesuch that the electrode formed is substantially U-shaped.

In Example 35, the subject matter of Example 33 is optionally configuredsuch that forming the electrode includes compressing the conductive tubesuch that the electrode formed is substantially T-shaped.

In Example 36, the subject matter of any one of Examples 33-35 isoptionally configured such that forming the electrode includescompressing the conductive tube into direct contact with the conductorwire.

In Example 37, the subject matter of any one of Examples 33-36optionally includes welding the connection portion of the conductor wireto the electrode.

In Example 38, the subject matter of Example 37 is optionally configuredsuch that welding the connection portion includes laser welding theconnection portion to the electrode.

In Example 39, the subject matter of Example 37 is optionally configuredsuch that welding the connection portion includes resistance welding theconnection portion to the electrode.

In Example 40, the subject matter of any one of Examples 33-40 isoptionally configured such that the conductive tube includes an innersurface facing inwardly toward an axis of the conductive tube and anouter surface facing outwardly away from the axis of the conductivetube. The connection portion of the conductor wire is coupled to a firstportion of the inner surface, wherein compressing the conductive tubeincludes compressing the conductive tube such that at least the firstportion of the inner surface and the connection portion of the conductorwire contacts at least a second portion of the inner surface tosubstantially sandwich the connection portion of the conductor wirebetween the first portion of the inner surface and the second portion ofthe inner surface.

In Example 41, the subject matter of any one of Examples 33-40 isoptionally configured such that forming the electrode includescompressing the conductive tube at least partially around the connectionportion of the conductor wire to constrain motion of the connectionportion of the conductor wire relative to the conductive tube.

In Example 42, the subject matter of any one of Examples 33-41 isoptionally configured such that forming the electrode includescompressing the conductive tube into direct contact with a couplingtube, the conductor wire being at least partially disposed within thecoupling tube.

In Example 43, the subject matter of Example 42 optionally includescoupling the conductor wire to the coupling tube.

In Example 44, the subject matter of Example 42 or 43 optionallyincludes welding the conductor wire to the coupling tube.

BRIEF DESCRIPTION OF THE DRAWINGS

FIGS. 1A and 1B show formation of an electrode in accordance with atleast one example of the invention.

FIG. 2 is a perspective view of an electrode in accordance with at leastone example of the invention.

FIG. 3 is a perspective view of a series of electrodes in accordancewith at least one example of the invention.

FIG. 4 is a perspective view of an electrode in accordance with at leastone example of the invention.

FIG. 5 is a perspective view of an electrode in accordance with at leastone example of the invention.

FIG. 6 is a perspective view of an electrode in accordance with at leastone example of the invention.

FIG. 7 is a side view of a distal end of a lead with electrodes inaccordance with at least one example of the invention.

FIG. 8 is a side view of a distal end of a lead with electrodes inaccordance with at least one example of the invention.

FIG. 9 is a perspective view of electrodes are formed around a conductorin accordance with at least one example of the invention.

FIGS. 10A-10C show formation of an electrode in accordance with at leastone example of the invention.

FIG. 11A is a perspective view of a lead including an electrode inaccordance with at least one example of the invention.

FIG. 11B is a side view of a lead including an electrode in accordancewith at least one example of the invention.

DETAILED DESCRIPTION

The present invention relates generally to providing a robust connectionbetween a conductor wire and an electrode in a device. Morespecifically, the present invention relates to the use of a connectionbetween a conductor wire and an electrode that inhibits breakage of theconductor wire and/or separation of the conductor wire from theelectrode, particularly within a heat affected zone (HAZ). As such, itis contemplated herein that the present subject matter can be usedwithin a device to inhibit premature breakage of the conductor wire orbreakage of the conductor wire from the electrode. In some examples,such a device can include a medical device; however, the presentinvention is not intended to be so limited as devices other than medicaldevices are contemplated herein.

In some examples, the purpose of the present invention is to connect aconductor wire to an electrode. In further examples, the conductor wireis connected to the electrode in a manner that can inhibit prematurebreakage of the conductor wire, such as, for instance breakage of theconductor wire within the HAZ. In some examples, an electrode connectionis formed in which the conductor wire is welded to the electrode, andthe electrode is then formed (for instance, collapsed down onto itself)to essentially sandwich the conductor wire between sides of theelectrode.

The present subject matter is advantageous in many respects. Forinstance, in some examples, the present subject matter allows for fasterproduction of a small electrode-to-wire connection and improved fatigueand durability characteristics of the electrode connection. In someexamples, the present subject matter advantageously inhibits, if notavoids, flexing of the conductor wire in the weld HAZ. In some examples,the present subject matter can also inhibit, if not eliminate, the needfor secondary welding due to a mechanical joint created during theforming of the electrode. That is, in some examples, forming ofelectrodes in conjunction with conductors creates a mechanicalconnection to the electrode, which can potentially eliminate welds, or,if welds are used, shield welds in the HAZ to reduce the likelihood offracture of the conductor wire.

In various examples, the present subject matter includes a connectionbetween a conductor wire and an electrode that reduces, if noteliminates, a chance of the conductor wire separating from theelectrode, for instance, due to breakage of the conductor wire in theHAZ. In other examples, the present subject matter includes a device orapparatus including one or more of such connections. In still otherexamples, the present subject matter includes a method of making such aconnection between a conductor wire and an electrode.

In some examples, the present subject matter can be used for one or moreelectrodes in an elongate device, such as, for instance a medicaldevice. In some examples, the medical device includes an at leastpartially implantable medical device. In further examples, the presentsubject matter can be used for one or more electrodes in a lead. Inother examples, the present subject matter can be used for one or moreelectrodes in a catheter.

In various examples described herein, electrodes can be formed, at leastin part, from platinum. In other examples, the electrodes described canbe formed from one or more materials, either in addition to or insteadof platinum, provided the materials are biocompatible and configured toproperly function to conduct electrical signals between the electrodeand tissue (including one or more of muscle tissue, nervous tissue,epithelial tissue, and/or connective tissue) of the patient. In someexamples, the electrodes described herein are shaped to form directionalelectrodes to allow stimulation from the electrodes to be directed in aspecific path from the example medical devices within which the one ormore electrodes are disposed.

In various examples described herein, conductor wires can be formed, atleast in part, from a nickel-cobalt alloy, such as, but not limited to,MP35N. In other examples, the conductor wires described can be formedfrom one or more materials, either in addition to or instead of anickel-cobalt alloy, provided the materials are configured to properlyfunction to conduct electrical signals between a pulse generator orother medical device and the electrode.

Referring to FIGS. 1A and 1B, in some examples, a component 100 isconfigured to be used with a medical device. In some examples, thecomponent includes a conductor wire 110 coupled to an electrode 140. Theconductor wire 110, in some examples, includes a proximal end (notshown), which, in various examples, can be coupled to electronic modules(in an external control unit, an implantable device, or the like) tocontrol operation of the electrode 140. In some examples, the conductorwire 110 includes a connection portion 114 configured for connection tothe electrode 140. That is, in some examples, the connection portion 114includes no insulation or at least insulation partially removed (thatis, a stripped or partially stripped portion of the conductor wire 110,such that bare wire of the conductor wire 110 is exposed) in order tofacilitate at least a reliable and contaminant-free electrical (if notalso mechanical) connection of the conductor wire 110 to the electrode140. In other examples, the connection portion 114 can be an insulatedportion of the conductor wire 110 and formation of the of the electrode140 and/or the component 100 can enable an electrical connection betweenthe connection portion 114 and the electrode 140. That is, in someexamples, welding of the connection portion 114 to the electrode 140vaporizes or otherwise at least partially removes the insulation of theconnection portion 114, thereby allowing the connection portion 114 tobe electrically coupled to the electrode 140. In other examples, eitherinstead of or in addition to welding of the connection portion 114 tothe electrode 140, compression of the electrode 140 onto the connectionportion 114 of the conductor wire 110 punctures, strips, or otherwisebreaches at least some of the insulation of the connector portion 114 toallow electrical coupling of the connection portion 114 to the electrode140. In some examples, the connection portion 114 is disposed proximatea distal end 110A of the conductor wire 110. In other examples, theconnection portion can be disposed at a portion of the conductor wire110 intermediate the proximal end and the distal end 110A of theconductor wire 110. In further examples, the conductor wire 110 caninclude two or more connection portions disposed along the conductorwire 110, for instance, to couple two or more electrodes 140 to theconductor wire 110.

In some examples, the electrode 140 is formed from a conductive tube130. In some examples, the conductive tube 130 can include asubstantially cylindrical tube. In other examples, the conductive tubecan include a differently shaped tube, including, but not limited to anoval-shaped tube, a box-shaped tube, a triangular-shaped tube, or thelike. In still other examples, instead of a conductive tube, theelectrode can be formed from a non-tubular substantially planarconductive sheet. In some examples, the conductive tube 130 iscompressed at least partially around the connection portion 114 of theconductor wire 110 to at least partially surround and couple to theconnection portion 114. In some examples, the compressing of theconductive tube 130 around the connection portion 114 mechanicallycouples the connection portion 114 of the conductor wire 110 to theconductive tube 130. In further examples, the compressing of theconductive tube 130 around the connection portion 114 also electricallycouples the connection portion 114 of the conductor wire 110 to theconductive tube 130. Alternatively, or in addition thereto, in someexamples, the connection portion 114 can be welded to the conductivetube 130 prior to compression of the conductive tube 130 (at weld 118)at least partially around the connection portion 114 of the conductorwire 110 and/or after compression of the conductive tube 130 (at weld119) at least partially around the connection portion 114 of theconductor wire 110. In some examples, the connection portion 114 islaser welded to the conductive tube 130. In other examples, theconnection portion 114 is resistance welded to the conductive tube 130.In this way, in some examples, the connector portion 114 of theconductor wire 110 is mechanically and electrically coupled to theconductive tube 130.

In some examples, as described above, welding of the conductor wire 110to the conductive tube 130 at the weld 118 prior to compression of theconductive tube 130 at least partially around the connection portion 114of the conductor wire 110 can create a heat affected zone (HAZ) 180. Theconductor wire 110 within the HAZ 180, in some examples, can become morebrittle and/or have an increased chance of breakage than a portion ofthe conductor wire 110 that is not within the HAZ 180. The presentsubject matter seeks to reduce the chances of such breakage of theconductor wire 110 and/or disconnection of the conductor wire 110 fromthe electrode 140 in the manners described herein.

In some examples, the conductive tube 130 is compressed into directcontact with the conductor wire 110. That is, in some examples, sides ofthe conductive tube 130 are pushed together to trap at least a portionof the conductor wire 110, and, namely, the connection portion 114 ofthe conductor wire 110, between the sides of the conductive tube 130, tothereby at least mechanically couple the conductor wire 110 to theconductive tube 130. In some examples, referring specifically to FIG.1B, the conductive tube 130 is compressed such that the electrode 140formed is substantially U-shaped. In some examples, the U-shapedconductive tube 130 forms the finished electrode 140. In other examples,the U-shaped conductive tube 130 is further formed, folded, and/ormanipulated into the intended shape for the electrode 140, dependingupon space constraints, a geometry, a size, a purpose, etc. of a devicewithin which the electrode 140 is to be used. As such, other shapes ofthe electrode are contemplated in other examples, at least some of whichare described below. In some examples, the electrode 140 includes asubstantially flat surface 144 configured to contact and stimulatetissue (including one or more of muscle tissue, nervous tissue,epithelial tissue, and/or connective tissue) of a patient and/or sense aphysiological signal or condition. That is, the electrode 140 includes asubstantially boxed-off U-shaped configuration included substantiallysquared-off corners.

In some examples, the conductive tube 130 includes an inner surface 134facing inwardly toward an axis 132 of the conductive tube 130 and anouter surface 136 facing outwardly away from the axis 132 of theconductive tube 130. In some examples, the connection portion 114 of theconductor wire 110 is coupled to a first portion 134A of the innersurface 134. In some examples, the electrode 140 includes the conductivetube 130 collapsed such that at least the first portion 134A of theinner surface 134 and the connection portion 114 of the conductor wire110 contact at least a second portion 134B of the inner surface 134 tosubstantially sandwich the connection portion 114 of the conductor wire110 between the first portion 134A of the inner surface 134 and thesecond portion 134B of the inner surface 134. In some examples, theconductive tube 130 is folded at least partially around the connectionportion 114 of the conductor wire 110 to form the electrode 140. In someexamples, the conductive tube 130 is compressed at least partiallyaround the connection portion 114 of the conductor wire 110 to constrainmotion of the connection portion 114 of the conductor wire 110 relativeto the conductive tube 130. In some examples, the connection portion 114is welded at the weld 119 to the electrode 140 after the conductive tube130 is compressed to form the electrode 140. Welding at the weld 119 canbe performed in addition to the weld 118 in some examples. In otherexamples, welding at the weld 119 can be performed instead of the weld118. In some examples, the connection portion 114 is laser welded to theelectrode 140. In other examples, the connection portion 114 isresistance welded to the electrode 140. In some examples, the weld 119is performed at an exterior 142 of the electrode 140, the weld 119passing through the conductive tube 130 to couple the connection portion114 of the conductor wire 110 to the electrode 140.

If welded at the weld 118, brittleness of the connection portion 114and/or the conductor wire 110 and the weld 118 can be counteracted byconstraining motion of the connector portion 114 with respect to theconductive tube 130. Limiting motion of the connection portion 114relative to the conductive tube 130 reduces, if not eliminates, thechance of the weld 118, the connection portion 114, and/or theconductive tube 130 breaking, rupturing, or otherwise separating todisrupt the connection between the conductor wire 110 and the electrode140 to disable the electrode 140 in the ultimate device in which theelectrode 140 is used. In many cases, an implanted device (such as, forinstance, an implantable lead in conjunction with an implantable pulsegenerator) in which an electrode fails must be explanted and replaced,which leads to increased cost and recovery due to the surgical procedurerequired for such explant and replacement. In other cases of temporaryand/or partial implantation (for instance, a catheter temporarilyimplanted in order to access a location within a patient), an electrodefailure can require the device to be removed and replaced with anotherdevice in order to perform the intended procedure. This can lead toincreased procedure time, patient risk, and cost due to having to usemultiple devices for one procedure. In this way, in some examples, thepresent subject matter increases the robustness of the electrode 140and, in turn, increases reliability of the ultimate device with whichthe electrode 140 is being used.

Referring to FIG. 2 , in some examples, a component 200 is configured tobe used with a medical device. The component 200, in some examples, issimilar in many respects to the component 100 described above, and, assuch, at least some of the description of the component 100 above canalso apply to the component 200. In some examples, the componentincludes a conductor wire 210 coupled to an electrode 240. In someexamples, the electrode 240 is formed from a conductive tube 230. Insome examples, the electrode 240 is formed in a manner similar to thatdescribed above with respect to the electrode 140. In some examples, theconductive tube 230 can include a substantially cylindrical tube. Inother examples, the conductive tube can include a differently shapedtube, including, but not limited to an oval-shaped tube, a box-shapedtube, a triangular-shaped tube, or the like. In still other examples,instead of a conductive tube, the electrode can be formed from anon-tubular substantially planar conductive sheet. In some examples, theconductive tube 230 is compressed at least partially around a connectionportion 214 of the conductor wire 210 to at least partially surround andcouple to the connection portion 214. In some examples, the conductorwire 210 is similar to the conductor wire 110 described above. In someexamples, the compressing of the conductive tube 230 around theconnection portion 214 mechanically couples the connection portion 214of the conductor wire 210 to the conductive tube 230. In furtherexamples, the compressing of the conductive tube 230 around theconnection portion 214 also electrically couples the connection portion214 of the conductor wire 210 to the conductive tube 230. Alternatively,or in addition thereto, in some examples, the connection portion 214 canbe welded to the conductive tube 230 prior to compression of theconductive tube 230 at least partially around the connection portion 214of the conductor wire 210 and/or after compression of the conductivetube 230 (at weld 219) at least partially around the connection portion214 of the conductor wire 210. In some examples, the connection portion214 is laser welded to the conductive tube 230. In other examples, theconnection portion 214 is resistance welded to the conductive tube 230.In this way, in some examples, the connector portion 214 of theconductor wire 210 is mechanically and electrically coupled to theconductive tube 230.

In some examples, as described above, welding of the conductor wire 210to the conductive tube 230 prior to compression of the conductive tube230 at least partially around the connection portion 214 of theconductor wire 210 can create a heat affected zone (HAZ). The conductorwire 210 within the HAZ, in some examples, can become more brittleand/or have an increased chance of breakage than a portion of theconductor wire 210 that is not within the HAZ. The present subjectmatter seeks to reduce the chances of such breakage of the conductorwire 210 and/or disconnection of the conductor wire 210 from theelectrode 240 in the manners described herein.

In some examples, the conductive tube 230 is compressed into directcontact with the conductor wire 210. That is, in some examples, sides ofthe conductive tube 230 are pushed together to trap at least a portionof the conductor wire 210, and, namely, the connection portion 214 ofthe conductor wire 210, between the sides of the conductive tube 230, tothereby at least mechanically couple the conductor wire 210 to theconductive tube 230. In some examples, the conductive tube 230 iscompressed such that the electrode 240 formed is substantially U-shaped.In some examples, the U-shaped conductive tube 230 forms the finishedelectrode 240. In other examples, the U-shaped conductive tube 230 isfurther formed, folded, and/or manipulated into the intended shape forthe electrode 240, depending upon space constraints, a geometry, a size,a purpose, etc. of a device within which the electrode 240 is to beused. As such, other shapes of the electrode are contemplated in otherexamples, at least some of which are described below. In some examples,the electrode 240 includes a rounded surface 244 configured to contactand stimulate tissue (including one or more of muscle tissue, nervoustissue, epithelial tissue, and/or connective tissue) of a patient and/orsense a physiological signal or condition. That is, the electrode 240includes a rounded substantially U-shaped configuration. In someexamples, the shape of the electrode 240 is substantially semicircularin cross section. In this regard, in some examples, the component 200 islargely similar to the component 100 but for the ultimate shape of theelectrode 240.

In some examples, the conductive tube 230 is folded at least partiallyaround the connection portion 214 of the conductor wire 210 to form theelectrode 240. In some examples, the conductive tube 230 is compressedat least partially around the connection portion 214 of the conductorwire 210 to constrain motion of the connection portion 214 of theconductor wire 210 relative to the conductive tube 230. In someexamples, the connection portion 214 is welded at the weld 219 to theelectrode 240 after the conductive tube 230 is compressed to form theelectrode 240. In some examples, the connection portion 214 is laserwelded at the weld 219 to the electrode 240. In other examples, theconnection portion 214 is resistance welded at the weld 219 to theelectrode 240. In some examples, the weld 219 is performed at anexterior 242 of the electrode 240, the weld 219 passing through theconductive tube 230 to couple the connection portion 214 of theconductor wire 210 to the electrode 240.

In this way, in various examples, motion of the connection portion 214relative to the conductive tube 230 is limited, thereby reducing, if noteliminating, the chance of the connection portion 214 and/or theconductive tube 230 breaking, rupturing, or otherwise separating todisrupt the connection between the conductor wire 210 and the electrode240 to disable the electrode 240 in the ultimate device in which theelectrode 240 is used. In this way, in some examples, the presentsubject matter increases the robustness of the electrode 240 and, inturn, increases reliability of the ultimate device with which theelectrode 240 is being used.

Referring now to FIG. 3 , an assembly 300 includes two or morecomponents 300A, 300B, 300C. In the example shown in FIG. 3 , theassembly 300 includes three components 300A, 300B, 300C; however, thisis merely illustrative as the component 300, in other examples, caninclude more or less than three components 300A, 300B, 300C. In someexamples, the two or more components 300A, 300B, 300C are similar inmany respects to the component 100 and/or the component 200 describedabove, and, as such, at least some of the description of the components100, 200 above can also apply to the two or more components 300A, 300B,300C. In some examples, each of the components 300A, 300B, 300C includesa conductor wire 310A, 310B, 310C coupled to an electrode 340A, 340B,340C. In some examples, with the two or more components 300A, 300B, 300Cof the assembly 300 used in an at least partially implantable elongatemember such as, but not limited to, a catheter, a lead, a guidewire, orthe like, the electrodes 340A, 340B, 340C of the assembly 300 can beused to stimulate tissue (including one or more of muscle tissue,nervous tissue, epithelial tissue, and/or connective tissue), sensephysiological conditions, or a combination thereof.

In some examples, the electrodes 340A, 340B, 340C are each formed fromconductive tubes 330A, 330B, 330C. In some examples, the electrodes340A, 340B, 340C are formed in a manner similar to that described abovewith respect to the electrode 140 or the electrode 240. In someexamples, each of the conductive tubes 330A, 330B, 330C are compressedat least partially around a connection portion 314A, 314B, 314C of eachof the conductor wires 310A, 310B, 310C to at least partially surroundand couple to the connection portion 314A, 314B, 314C. In some examples,the compressing of each of the conductive tubes 330A, 330B, 330C aroundthe connection portions 314A, 314B, 314C, respectively, mechanicallycouples the connection portions 314A, 314B, 314C of the conductor wires310A, 310B, 310C to the conductive tubes 330A, 330B, 330C. In furtherexamples, the compressing of the conductive tubes 330A, 330B, 330Caround the connection portions 314A, 314B, 314C, respectively, alsoelectrically couples the connection portions 314A, 314B, 314C of theconductor wires 310A, 310B, 310C to the conductive tubes 330A, 330B,330C. Alternatively, or in addition thereto, in some examples, one ormore of the connection portions 314A, 314B, 314C can be welded to one ormore of the conductive tubes 330A, 330B, 330C, respectively, prior tocompression of the conductive tube 330A, 330B, 330C at least partiallyaround the connection portion 314A, 314B, 314C of the conductor wire310A, 310B, 310C and/or after compression of the conductive tube 330A,330B, 330C (at weld 319A, 319B, 319C) at least partially around theconnection portion 314A, 314B, 314C of the conductor wire 310A, 310B,310C. In some examples, the two or more connection portions 314A, 314B,314C are laser welded to the respective two or more conductive tubes330A, 330B, 330C. In other examples, the two or more connection portions314A, 314B, 314C are resistance welded to the respective two or moreconductive tubes 330A, 330B, 330C. In this way, in some examples, theconnector portions 314A, 314B, 314C of the conductor wires 310A, 310B,310C are mechanically and electrically coupled to the respectiveconductive tubes 330A, 330B, 330C.

In some examples, the conductive tubes 330A, 330B, 330C are compressedinto direct contact with the respective conductor wires 310A, 310B,310C. That is, in some examples, sides of each of the conductive tubes330A, 330B, 330C are pushed together to trap at least a portion of therespective conductor wire 310A, 310B, 310C, and, namely, the connectionportion 314A, 314B, 314C of the conductor wire 310A, 310B, 310C, betweenthe sides of the conductive tube 330A, 330B, 330C, to thereby at leastmechanically couple the conductor wire 310A, 310B, 310C to theconductive tube 330A, 330B, 330C. In some examples, the conductive tube330A, 330B, 330C is compressed such that the electrode 340A, 340B, 340Cformed is substantially U-shaped. In some examples, the two or moreU-shaped conductive tubes 330A, 330B, 330C form the two or more finishedelectrodes 340A, 340B, 340C. In other examples, the U-shaped conductivetube 330A, 330B, 330C is further formed, folded, and/or manipulated intothe intended shape for the electrode 340A, 340B, 340C, depending uponspace constraints, a geometry, a size, a purpose, etc. of a devicewithin which the electrode 340A, 340B, 340C is to be used. As such,other shapes of the electrode are contemplated in other examples, atleast some of which are described below. In some examples, the two ormore electrodes 340A, 340B, 340C each include a rounded surface 344A,344B, 344C configured to contact and stimulate tissue (including one ormore of muscle tissue, nervous tissue, epithelial tissue, and/orconnective tissue) of a patient and/or sense a physiological signal orcondition. That is, in some examples, the two or more electrodes 340A,340B, 340C each include a rounded substantially U-shaped configuration.In some examples, the shape of the two or more electrodes 340A, 340B,340C is substantially semicircular in cross section. In this regard, insome examples, the two or more components 300A, 300B, 300C are largelysimilar to the component 200 described above. In other examples, the twoor more electrodes 340A, 340B, 340C include at least one electrode thatis differently shaped from at least another electrode, for instance, ifsuch a configuration is beneficial with respect to a particularapplication.

In some examples, each of the conductive tubes 330A, 330B, 330C isfolded at least partially around the respective connection portion 314A,314B, 314C of the conductor wire 310A, 310B, 310C to form the electrode340A, 340B, 340C. In some examples, the two or more conductive tubes330A, 330B, 330C are compressed at least partially around the respectiveconnection portions 314A, 314B, 314C of the conductor wires 310A, 310B,310C to constrain motion of the connection portions 314A, 314B, 314C ofthe conductor wires 310A, 310B, 310C relative to the respectiveconductive tubes 330A, 330B, 330C. In some examples, each of the two ormore connection portions 314A, 314B, 314C is welded at the weld 319A,319B, 319C to the respective electrode 340A, 340B, 340C after theconductive tube 330A, 330B, 330C is compressed to form the electrode340A, 340B, 340C. In some examples, each of the two or more connectionportions 314A, 314B, 314C is laser welded at the weld 319A, 319B, 319Cto the respective electrode 340A, 340B, 340C. In other examples, each ofthe two or more connection portions 314A, 314B, 314C is resistancewelded at the weld 319A, 319B, 319C to the respective electrode 340A,340B, 340C. In some examples, each of the welds 319A, 319B, 319C isperformed at an exterior 342A, 342B, 342C of the electrode 340A, 340B,340C, the welds 319A, 319B, 319C passing through the respectiveconductive tubes 330A, 330B, 330C to couple the connection portion 314A,314B, 314C of the conductor wire 310A, 310B, 310C to the electrode 340A,340B, 340C.

In this way, in various examples, motion of the two or more connectionportions 314A, 314B, 314C relative to the respective conductive tubes330A, 330B, 330C is limited, thereby reducing, if not eliminating, thechance of the connection portions 314A, 314B, 314C and/or the conductivetubes 330A, 330B, 330C breaking, rupturing, or otherwise separating todisrupt the respective connections between the conductor wires 310A,310B, 310C and the electrodes 340A, 340B, 340C to disable any of theelectrodes 340A, 340B, 340C in the ultimate device in which theelectrodes 340A, 340B, 340C of the assembly 300 are used. In this way,in some examples, the present subject matter increases the robustness ofthe two or more electrodes 340A, 340B, 340C of the assembly 300 and, inturn, increases reliability of the ultimate device with which theelectrodes 340A, 340B, 340C of the assembly 300 are being used.

Referring now to FIGS. 4-6 , various examples of components 400, 500,600 with differently-shaped electrodes 440, 540, 640 are shown. In someexamples, one or more of the electrodes 440, 540, 640 can be used withthe components 100, 200 and/or the assembly 300 described above, eitherin addition to, or instead of, the electrodes 140, 240, 340A, 340B, 340Cdescribed above. In some examples, the components 400, 500, 600 aresimilar in many respects to the component 100, the component 200, and/orthe components 300A, 300B, 300C described above, and, as such, at leastsome of the description of the components 100, 200, 300A, 300B, 300Cabove can also apply to the components 400, 500, 600.

Referring specifically to FIG. 4 , the component 400 includes theelectrode 440 coupled to a conductor wire 410. In some examples, theelectrode 440 is formed from a conductive tube 430. In some examples,the conductive tube 430 is compressed at least partially around aconnection portion of the conductor wire 410 to at least partiallysurround and couple to the connection portion. In some examples, thecompressing of the conductive tube 430 around the connection portionmechanically couples the connection portion of the conductor wire 410 tothe conductive tube 430. In further examples, the compressing of theconductive tube 430 around the connection portion also electricallycouples the connection portion of the conductor wire 410 to theconductive tube 430. Alternatively, or in addition thereto, in someexamples, the connection portion can be welded to the conductive tube430 prior to compression of the conductive tube 430 at least partiallyaround the connection portion of the conductor wire 410 and/or aftercompression of the conductive tube 430 at least partially around theconnection portion of the conductor wire 410. In some examples, theconnection portion is laser welded to the conductive tube 430. In otherexamples, the connection portion is resistance welded to the conductivetube 430. In this way, in some examples, the connector portion of theconductor wire 410 is mechanically and electrically coupled to theconductive tube 430.

In some examples, as described above, welding of the conductor wire 410to the conductive tube 430 prior to compression of the conductive tube430 at least partially around the connection portion of the conductorwire 410 can create a heat affected zone (HAZ). The conductor wire 410within the HAZ, in some examples, can become more brittle and/or have anincreased chance of breakage than a portion of the conductor wire 410that is not within the HAZ. The present subject matter seeks to reducethe chances of such breakage of the conductor wire 410 and/ordisconnection of the conductor wire 410 from the electrode 440 in themanners described herein.

In some examples, the conductive tube 430 is compressed into directcontact with the conductor wire 410. That is, in some examples, sides ofthe conductive tube 430 are pushed together to trap at least a portionof the conductor wire 410, and, namely, the connection portion of theconductor wire 410, between the sides of the conductive tube 430, tothereby at least mechanically couple the conductor wire 410 to theconductive tube 430. In some examples, the conductive tube 430 iscompressed such that the electrode 440 formed is substantially T-shaped.In some examples, the electrode 440 includes a substantially flatsurface 444 configured to contact and stimulate tissue (including one ormore of muscle tissue, nervous tissue, epithelial tissue, and/orconnective tissue) of a patient and/or sense a physiological signal orcondition. In some examples, the conductive tube 430 is compressed toform the T-shape with the conductor wire 410 disposed within a leg 445of the T-shape extending from the portion of the T-shape that forms thesubstantially flat surface 444. In some examples, the conductor wire 410is disposed at an end of the leg 445 of the T-shape.

In some examples, the T-shaped conductive tube 430 forms the finishedelectrode 440. In other examples, the T-shaped conductive tube 430 isfurther formed, folded, and/or manipulated into the intended shape forthe electrode 440, depending upon space constraints, a geometry, a size,a purpose, etc. of a device within which the electrode 440 is to beused. As such, other shapes of the electrode are contemplated in otherexamples, at least some of which are described herein.

In some examples, the conductive tube 430 includes an inner surface 434facing inwardly from the conductive tube 430 and an outer surface 436facing outwardly from the conductive tube 430. In some examples, theconnection portion of the conductor wire 410 is coupled to a firstportion 434A of the inner surface 434. In some examples, the electrode440 includes the conductive tube 430 collapsed such that at least thefirst portion 434A of the inner surface 434 and the connection portionof the conductor wire 410 contacts at least a second portion 434B of theinner surface 434 to substantially sandwich the connection portion ofthe conductor wire 410 between the first portion 434A of the innersurface 434 and the second portion 434B of the inner surface 434. Insome examples, the conductive tube 430 is folded at least partiallyaround the connection portion of the conductor wire 410 to form theelectrode 440. In some examples, the conductive tube 430 is compressedat least partially around the connection portion of the conductor wire410 to constrain motion of the connection portion of the conductor wire410 relative to the conductive tube 430. In some examples, theconnection portion is welded at a weld 419 to the electrode 440 afterthe conductive tube 430 is compressed to form the electrode 440.

Welding at the weld 419 can be performed in addition to welding theconnection portion of the conductor wire 410 to the conductive tube 430prior to formation of the electrode 440, in some examples. In otherexamples, welding at the weld 419 can be performed instead of weldingthe connection portion of the conductor wire 410 to the conductive tube430 prior to formation of the electrode 440. In some examples, theconnection portion is laser welded to the electrode 440. In otherexamples, the connection portion is resistance welded to the electrode440. In some examples, the weld 419 is performed at an exterior 442 ofthe electrode 440, the weld 419 passing through the conductive tube 430to couple the connection portion of the conductor wire 410 to theelectrode 440.

In some examples, welding can cause brittleness of the connectionportion and/or the conductor wire 410 and the weld, which can becounteracted by constraining motion of the connector portion withrespect to the conductive tube 430. Limiting motion of the connectionportion relative to the conductive tube 430 reduces, if not eliminates,the chance of the weld, the connection portion, and/or the conductivetube 430 breaking, rupturing, or otherwise separating to disrupt theconnection between the conductor wire 410 and the electrode 440 todisable the electrode 440 in the ultimate device in which the electrode440 is used. In many cases, an implanted device (such as, for instance,an implantable lead in conjunction with an implantable pulse generator)in which an electrode fails must be explanted and replaced, which leadsto increased cost and recovery due to the surgical procedure requiredfor such explant and replacement. In other cases of temporary and/orpartial implantation (for instance, a catheter temporarily implanted inorder to access a location within a patient), an electrode failure canrequire the device to be removed and replaced with another device inorder to perform the intended procedure. This can lead to increasedprocedure time, patient risk, and cost due to having to use multipledevices for one procedure. In this way, in some examples, the presentsubject matter increases the robustness of the electrode 440 and, inturn, increases reliability of the ultimate device with which theelectrode 440 is being used.

Referring now to FIG. 5 , the component 500 includes the electrode 540coupled to a conductor wire 510. In some examples, the electrode 540 isformed from a conductive tube 530. In some examples, the conductive tube530 is compressed at least partially around a connection portion 514 ofthe conductor wire 510 to at least partially surround and couple to theconnection portion 514. In some examples, the compressing of theconductive tube 530 around the connection portion 514 mechanicallycouples the connection portion 514 of the conductor wire 510 to theconductive tube 530. In further examples, the compressing of theconductive tube 530 around the connection portion 514 also electricallycouples the connection portion 514 of the conductor wire 510 to theconductive tube 530. Alternatively, or in addition thereto, in someexamples, the connection portion 514 can be welded to the conductivetube 530 prior to compression of the conductive tube 530 at leastpartially around the connection portion 514 of the conductor wire 510and/or after compression of the conductive tube 530 at least partiallyaround the connection portion 514 of the conductor wire 510. In someexamples, the connection portion 514 is laser welded to the conductivetube 530. In other examples, the connection portion 514 is resistancewelded to the conductive tube 530. In this way, in some examples, theconnector portion 514 of the conductor wire 510 is mechanically andelectrically coupled to the conductive tube 530.

In some examples, as described above, welding of the conductor wire 510to the conductive tube 530 prior to compression of the conductive tube530 at least partially around the connection portion 514 of theconductor wire 510 can create a heat affected zone (HAZ). The conductorwire 510 within the HAZ, in some examples, can become more brittleand/or have an increased chance of breakage than a portion of theconductor wire 510 that is not within the HAZ. The present subjectmatter seeks to reduce the chances of such breakage of the conductorwire 510 and/or disconnection of the conductor wire 510 from theelectrode 540 in the manners described herein.

In some examples, the conductive tube 530 is compressed into directcontact with the conductor wire 510. That is, in some examples, sides ofthe conductive tube 530 are pushed together to trap at least a portionof the conductor wire 510, and, namely, the connection portion 514 ofthe conductor wire 510, between the sides of the conductive tube 530, tothereby at least mechanically couple the conductor wire 510 to theconductive tube 530. In some examples, the conductive tube 530 iscompressed such that the electrode 540 formed is substantiallyring-shaped. In some examples, the electrode 540 includes a roundedsurface 544 configured to contact and stimulate tissue (including one ormore of muscle tissue, nervous tissue, epithelial tissue, and/orconnective tissue) of a patient and/or sense a physiological signal orcondition.

In some examples, the ring-shaped conductive tube 530 forms the finishedelectrode 540. In other examples, the ring-shaped conductive tube 530 isfurther formed, folded, and/or manipulated into the intended shape forthe electrode 540, depending upon space constraints, a geometry, a size,a purpose, etc. of a device within which the electrode 540 is to beused. As such, other shapes of the electrode are contemplated in otherexamples, at least some of which are described herein.

In some examples, the conductive tube 530 includes an inner surface 534facing inwardly from the conductive tube 530 and an outer surface 536facing outwardly from the conductive tube 530. In some examples, theconnection portion 514 of the conductor wire 510 is coupled to a firstportion 536A of the outer surface 536. In some examples, the electrode540 includes the conductive tube 530 formed such that at least the firstportion 536A of the outer surface 536 wraps at least partially aroundthe connection portion 514 of the conductor wire 510 to form a channelwithin which the connection portion 514 of the conductor wire 510 can bedisposed. In some examples, the conductive tube 530 can be formed towrap more than 180 degrees around the connection portion 514 of theconductor wire 510 to at least partially capture the connection portion514 of the conductor wire 510 within the channel. In some examples, theconductive tube 530 can be formed to wrap substantially 360 degreesaround the connection portion 514 of the conductor wire 510 tosubstantially fully capture the connection portion 514 of the conductorwire 510 within the channel. In this way, in some examples, compressionof the conductive tube 530 can constrain motion of the connectionportion 514 of the conductor wire 510 relative to the conductive tube530. In some examples, the connection portion 514 is welded to theelectrode 540 after the conductive tube 530 is compressed to form theelectrode 540.

Welding can be performed in addition to welding the connection portion514 of the conductor wire 510 to the conductive tube 530 prior toformation of the electrode 540, in some examples. In other examples,welding can be performed instead of welding the connection portion 514of the conductor wire 510 to the conductive tube 530 prior to formationof the electrode 540. In some examples, the connection portion 514 islaser welded to the electrode 540. In other examples, the connectionportion 514 is resistance welded to the electrode 540. In some examples,the weld is performed at an interior 543 of the electrode 540, the weldpassing through the conductive tube 530 to couple the connection portion514 of the conductor wire 510 to the electrode 540. In other examples,either instead of or in addition to the weld through the conductive tube530 from the interior 543 of the electrode 540, the connection portion514 of the conductor wire 510 can be welded to the electrode 540 at anexterior 542 of the electrode 540.

In some examples, welding can cause brittleness of the connectionportion 514 and/or the conductor wire 510 and the weld, which can becounteracted by constraining motion of the connector portion withrespect to the conductive tube 530. Limiting motion of the connectionportion 514 relative to the conductive tube 530 reduces, if noteliminates, the chance of the weld, the connection portion 514, and/orthe conductive tube 530 breaking, rupturing, or otherwise separating todisrupt the connection between the conductor wire 510 and the electrode540 to disable the electrode 540 in the ultimate device in which theelectrode 540 is used. In many cases, an implanted device (such as, forinstance, an implantable lead in conjunction with an implantable pulsegenerator) in which an electrode fails must be explanted and replaced,which leads to increased cost and recovery due to the surgical procedurerequired for such explant and replacement. In other cases of temporaryand/or partial implantation (for instance, a catheter temporarilyimplanted in order to access a location within a patient), an electrodefailure can require the device to be removed and replaced with anotherdevice in order to perform the intended procedure. This can lead toincreased procedure time, patient risk, and cost due to having to usemultiple devices for one procedure. In this way, in some examples, thepresent subject matter increases the robustness of the electrode 540and, in turn, increases reliability of the ultimate device with whichthe electrode 540 is being used.

Referring now to FIG. 6 , the component 600 includes the electrode 640coupled to a conductor wire 610. In some examples, the electrode 640 isformed from a conductive tube 630. In some examples, the conductive tube630 is compressed at least partially around a connection portion of theconductor wire 610 to at least partially surround and couple to theconnection portion. In some examples, the compressing of the conductivetube 630 around the connection portion mechanically couples theconnection portion of the conductor wire 610 to the conductive tube 630.In further examples, the compressing of the conductive tube 630 aroundthe connection portion also electrically couples the connection portionof the conductor wire 610 to the conductive tube 630. Alternatively, orin addition thereto, in some examples, the connection portion can bewelded to the conductive tube 630 prior to compression of the conductivetube 630 at least partially around the connection portion of theconductor wire 610 and/or after compression of the conductive tube 630at least partially around the connection portion of the conductor wire610. In some examples, the connection portion is laser welded to theconductive tube 630. In other examples, the connection portion isresistance welded to the conductive tube 630. In this way, in someexamples, the connector portion of the conductor wire 610 ismechanically and electrically coupled to the conductive tube 630.

In some examples, as described above, welding of the conductor wire 610to the conductive tube 630 prior to compression of the conductive tube630 at least partially around the connection portion of the conductorwire 610 can create a heat affected zone (HAZ). The conductor wire 610within the HAZ, in some examples, can become more brittle and/or have anincreased chance of breakage than a portion of the conductor wire 610that is not within the HAZ. The present subject matter seeks to reducethe chances of such breakage of the conductor wire 610 and/ordisconnection of the conductor wire 610 from the electrode 640 in themanners described herein.

In some examples, the conductive tube 630 is compressed into directcontact with the conductor wire 610. That is, in some examples, sides ofthe conductive tube 630 are pushed together to trap at least a portionof the conductor wire 610, and, namely, the connection portion of theconductor wire 610, between the sides of the conductive tube 630, tothereby at least mechanically couple the conductor wire 610 to theconductive tube 630. In some examples, the conductive tube 630 iscompressed such that the electrode 640 formed is substantiallyflattened. That is, in some examples, the conductive tube 630 iscompressed down so that an inner surface 634 facing inwardly from theconductive tube 630 substantially abuts itself along a diameter of theconductive tube 630. In some examples, the conductive tube 630 isfurther folded so that a portion of an outer surface 636 facingoutwardly from the conductive tube 630 abuts another portion of theouter surface 636. In some examples, the conductive tube 630 is foldedsubstantially in half in this process. In other examples, the conductivetube 630 is folded in other proportions in this process. In still otherexamples, the conductive tube 630 need not be further folded, such thatthe conductive tube 630 compressed down so that the inner surface 634substantially abuts itself along a diameter of the conductive tube 630forms the finished electrode 640. In some examples, the electrode 640includes a substantially flat surface 644 configured to contact andstimulate tissue (including one or more of muscle tissue, nervoustissue, epithelial tissue, and/or connective tissue) of a patient and/orsense a physiological signal or condition. In some examples, theconductive tube 630 is compressed to form the flattened shape with theconductor wire 610 disposed at an end of the flattened conductive tube630 of the electrode 640.

In some examples, the flattened conductive tube 630 forms the finishedelectrode 640. In other examples, the flattened conductive tube 630 isfurther formed, folded, and/or manipulated into the intended shape forthe electrode 640, depending upon space constraints, a geometry, a size,a purpose, etc. of a device within which the electrode 640 is to beused. As such, other shapes of the electrode are contemplated in otherexamples, at least some of which are described herein.

In some examples, the connection portion of the conductor wire 610 iscoupled to a first portion 634A of the inner surface 634. In someexamples, the electrode 640 includes the conductive tube 630 collapsedsuch that at least the first portion 634A of the inner surface 634 andthe connection portion of the conductor wire 610 contacts at least asecond portion 634B of the inner surface 634 to substantially sandwichthe connection portion of the conductor wire 610 between the firstportion 634A of the inner surface 634 and the second portion 634B of theinner surface 634. In some examples, the conductive tube 630 is foldedat least partially around the connection portion of the conductor wire610 to form the electrode 640. In some examples, the conductive tube 630is compressed at least partially around the connection portion of theconductor wire 610 to constrain motion of the connection portion of theconductor wire 610 relative to the conductive tube 630. In someexamples, the connection portion is welded to the electrode 640 afterthe conductive tube 630 is compressed to form the electrode 640.

Welding can be performed in addition to welding the connection portionof the conductor wire 610 to the conductive tube 630 prior to formationof the electrode 640, in some examples. In other examples, welding canbe performed instead of welding the connection portion of the conductorwire 610 to the conductive tube 630 prior to formation of the electrode640. In some examples, the connection portion is laser welded to theelectrode 640. In other examples, the connection portion is resistancewelded to the electrode 640. In some examples, the weld is performed atan exterior 642 of the electrode 640, the weld passing through theconductive tube 630 to couple the connection portion of the conductorwire 610 to the electrode 640.

In some examples, welding can cause brittleness of the connectionportion and/or the conductor wire 610 and the weld, which can becounteracted by constraining motion of the connector portion withrespect to the conductive tube 630. Limiting motion of the connectionportion relative to the conductive tube 630 reduces, if not eliminates,the chance of the weld, the connection portion, and/or the conductivetube 630 breaking, rupturing, or otherwise separating to disrupt theconnection between the conductor wire 610 and the electrode 640 todisable the electrode 640 in the ultimate device in which the electrode640 is used. In many cases, an implanted device (such as, for instance,an implantable lead in conjunction with an implantable pulse generator)in which an electrode fails must be explanted and replaced, which leadsto increased cost and recovery due to the surgical procedure requiredfor such explant and replacement. In other cases of temporary and/orpartial implantation (for instance, a catheter temporarily implanted inorder to access a location within a patient), an electrode failure canrequire the device to be removed and replaced with another device inorder to perform the intended procedure. This can lead to increasedprocedure time, patient risk, and cost due to having to use multipledevices for one procedure. In this way, in some examples, the presentsubject matter increases the robustness of the electrode 640 and, inturn, increases reliability of the ultimate device with which theelectrode 640 is being used.

Referring to FIG. 7 , in some examples, as described herein, thepresently-described subject matter can be used in a medical device 700.That is, one or more electrodes 740 can be disposed within the medicaldevice 700, the medical device 700 being configured for at least partialimplantation within a patient. Although the medical device 700 of FIG. 7includes three electrodes 740, this is merely illustrative. In variousexamples, the medical device 700 can include more or fewer than threeelectrodes 740 depending upon the application for which the medicaldevice 700 is to be used.

The medical device 700, in some examples, can include an elongatemedical device 700 including an elongate body 702 including a distal end702A and a proximal end 702B. In various examples, the elongate medicaldevice 700 can include an elongate lead; an elongate catheter,introducer, sheath, or the like; a guidewire; etc. In some examples, theone or more electrodes 740 are disposed proximate the distal end 702A ofthe medical device 700. In some examples, the one or more electrodes 740are connected by conductor wires 710 to a corresponding number ofcontacts 760. In some examples, the one or more contacts 760 aredisposed proximate the distal end 702B of the medical device 700. Theone or more contacts 760, in some examples, are configured toelectrically couple with another medical device (not shown), such as,for instance, a pulse generator, a medical monitor, a mapping device, orthe like, either implantable or external, to, in turn, electricallycouple the one or more electrodes 740 to the pulse generator, a medicalmonitor, a mapping device, etc. and enable the one or more electrodes740 to stimulate tissue (including one or more of muscle tissue, nervoustissue, epithelial tissue, and/or connective tissue) of a patient and/orsense a physiological signal or condition of the patient.

In some examples, the one or more electrodes 740 are each disposedwithin the medical device 700 with at least an electrode surface 744being exposed to an exterior of the medical device 700. In someexamples, the electrode surface 744 of each of the one or moreelectrodes 740 is a rounded surface 744 configured to contact andstimulate tissue of a patient and/or sense a physiological signal orcondition. In various examples, the one or more electrodes 740 can besimilarly shaped to one or more of the examples of electrodes describedabove, such as, but not limited the electrodes 240, 340, 540. In otherexamples, the one or more electrodes 740 can have rounded surfaces 744differently shaped from those of the electrodes 240, 340, 540, providedthe medical device 700 is capable of properly functioning for theapplication for which the medical device 700 is being used.

Referring to FIG. 8 , in some examples, as described herein, thepresently-described subject matter can be used in a medical device 800.That is, one or more electrodes 840 can be disposed within the medicaldevice 800, the medical device 800 being configured for at least partialimplantation within a patient. Although the medical device 800 of FIG. 8includes three electrodes 840, this is merely illustrative. In variousexamples, the medical device 800 can include more or fewer than threeelectrodes 840 depending upon the application for which the medicaldevice 800 is to be used.

The medical device 800, in some examples, can include an elongatemedical device 800 including an elongate body 802 including a distal end802A and a proximal end 802B. In various examples, the elongate medicaldevice 800 can include an elongate lead; an elongate catheter,introducer, sheath, or the like; a guidewire; etc. In some examples, theone or more electrodes 840 are disposed proximate the distal end 802A ofthe medical device 800. In some examples, the one or more electrodes 840are connected by conductor wires 810 to a corresponding number ofcontacts 860. In some examples, the one or more contacts 860 aredisposed proximate the distal end 802B of the medical device 800. Theone or more contacts 860, in some examples, are configured toelectrically couple with another medical device (not shown), such as,for instance, a pulse generator, a medical monitor, a mapping device, orthe like, either implantable or external, to, in turn, electricallycouple the one or more electrodes 840 to the pulse generator, a medicalmonitor, a mapping device, etc. and enable the one or more electrodes840 to stimulate tissue (including one or more of muscle tissue, nervoustissue, epithelial tissue, and/or connective tissue) of a patient and/orsense a physiological signal or condition of the patient.

In some examples, the one or more electrodes 840 are each disposedwithin the medical device 800 with at least an electrode surface 844being exposed to an exterior of the medical device 800. In someexamples, the electrode surface 844 of each of the one or moreelectrodes 840 is a substantially flat surface 844 configured to contactand stimulate tissue of a patient and/or sense a physiological signal orcondition. In various examples, the one or more electrodes 840 can besimilarly shaped to one or more of the examples of electrodes describedabove, such as, but not limited the electrodes 140, 440, 640. In otherexamples, the one or more electrodes 840 can have substantially flatsurfaces 844 differently shaped from those of the electrodes 140, 440,640, provided the medical device 800 is capable of properly functioningfor the application for which the medical device 800 is being used.

Referring to FIG. 9 , an assembly 900 includes one or more components orelectrodes 940. In the example shown in FIG. 9 , the assembly 900includes eight electrodes 940; however, this is merely illustrative asthe assembly 900, in other examples, can include more or less than eightelectrodes 940. In some examples, the one or more electrodes 940 can besimilar to one or more of the example electrodes 140, 240, 340A, 340B,340C, 440, 540, 640, 740, 840 described above, and, as such, variousaspects of the description of the electrodes 140, 240, 340A, 340B, 340C,440, 540, 640, 740, 840 above can also apply to the one or moreelectrodes 940. In some examples, a conductor coil 910 is coupled to theone or more electrodes 940. In some examples, the electrodes 940 areformed around the conductor coil 910 and then welded (laser orresistance welded, for instance) to the conductor coil 910. In someexamples, all of the electrodes 940 are connected to a single conductorwire of the conductor coil 910. In other examples, the conductor coil910 is formed from multiple conductors with a different conductor beingattached to each of the electrodes 940. In some examples, with the oneor more electrodes 940 of the assembly 900 used in an at least partiallyimplantable elongate member such as, but not limited to, a catheter, asheath, an introducer, a lead, a guidewire, or the like, the one or moreelectrodes 940 of the assembly 900 can be used to stimulate tissue(including one or more of muscle tissue, nervous tissue, epithelialtissue, and/or connective tissue), sense physiological conditions, or acombination thereof.

Referring now to FIGS. 10A-10C, in some examples, a component 1000includes an electrode 1040 coupled to a conductor wire 1010. In someexamples, the electrode 1040 is formed from a conductive tube 1030. Insome examples, the conductive tube 1030 is compressed at least partiallyaround a coupling tube 1050. In some examples, the conductive tube 1030is compressed into direct contact with the coupling tube 1050. In someexamples, the conductive tube 1030 is folded at least partially aroundthe coupling tube 1050 within which the connection portion of theconductor wire 1010 can be disposed to form the electrode 1040. In someexamples, the conductive tube 1030 is crimped around the coupling tube1050 to couple the coupling tube 1050 to the conductive tube 1030. Insome examples, the conductive tube 1030 is welded to the coupling tube1050 to couple the coupling tube 1050 to the conductive tube 1030,either in addition to, or instead of, crimping the conductive tube 1030at least partially around the coupling tube 1050. In some examples, theconductive tube 1030 includes an inner surface 1034 facing inwardlytoward an axis 1032 of the conductive tube 1030 and an outer surface1036 facing outwardly away from the axis 1032 of the conductive tube1030. In some examples, the coupling tube 1050 is coupled to a firstportion 1034A of the inner surface 1034. In some examples, the electrode1040 includes the conductive tube 1030 collapsed such that at least thefirst portion 1034A of the inner surface 1034 and the coupling tube 1050contact at least a second portion 1034B of the inner surface 1034 tosubstantially sandwich the coupling tube 1050 between the first portion1034A of the inner surface 1034 and the second portion 1034B of theinner surface 1034.

The coupling tube 1050, in some examples, is configured to accept theconductor wire 1010 within the coupling tube 1050, such that aconnection portion of the conductor wire 1010 is at least partiallydisposed within the coupling tube 1050 of the completed component 1000.In some examples, the conductor wire 1010 is coupled to the couplingtube 1050. In some examples, the coupling tube 1050 can be crimped ontothe conductor wire 1010. In other examples, the conductor wire 1010 canbe welded to the coupling tube 1050, in addition to, or instead of,crimping the conductor wire 1010 to the coupling tube 1050. In someexamples, the connection portion of the conductor wire 1010 is laserwelded to the coupling tube 1050. In other examples, the connectionportion of the conductor wire 1010 is resistance welded to the couplingtube 1050. In this way, the connection portion of the conductor wire1010 is mechanically and electrically coupled to the coupling tube 1050,which, in turn, is mechanically and/or electrically coupled to theconductive tube 1030.

In some examples, the conductive tube 1030 is compressed such that theelectrode 1040 formed is substantially T-shaped. In some examples, theelectrode 1040 includes a substantially flat surface 1044 configured tocontact and stimulate tissue (including one or more of muscle tissue,nervous tissue, epithelial tissue, and/or connective tissue) of apatient and/or sense a physiological signal or condition. In someexamples, the conductive tube 1030 is compressed to form the T-shapewith the coupling tube 1050 disposed within a leg 1045 of the T-shapeextending from the portion of the T-shape that forms the substantiallyflat surface 1044. In some examples, the coupling tube 1050 is disposedat an end of the leg 1045 of the T-shape.

In some examples, the T-shaped conductive tube 1030 forms the finishedelectrode 1040. In other examples, the T-shaped conductive tube 1030 isfurther formed, folded, and/or manipulated into the intended shape forthe electrode 1040, depending upon space constraints, a geometry, asize, a purpose, etc. of a device within which the electrode 1040 is tobe used. As such, other shapes of the electrode are contemplated inother examples, at least some of which are described herein.

In this way, in some examples, the electrode 1040 with the coupling tube1050 can reduce, if not eliminate, the need for welding to form thecomponent 1000, which, in turn, reduces, if not eliminates, the effectsof a heat affected zone (HAZ), as described above with respect to otherexamples of components. In examples where welding is used, brittleness(of the weld, the conductor wire 1010, etc.) caused can be counteractedby constraining motion of the connector portion of the conductor wire1010 with respect to the conductive tube 1030 and/or the coupling tube1050. Limiting motion of the connection portion relative to theconductive tube 1030 and/or the coupling tube 1050 reduces, if noteliminates, the chance of the weld, the connection portion, theconductive tube 1030, and/or the coupling tube 1050 breaking, rupturing,or otherwise separating to disrupt the connection between the conductorwire 1010 and the electrode 1040, leading to the disabling of theelectrode 1040 in the ultimate device in which the electrode 1040 isused. In many cases, an implanted device (such as, for instance, animplantable lead in conjunction with an implantable pulse generator) inwhich an electrode fails must be explanted and replaced, which leads toincreased cost and recovery due to the surgical procedure required forsuch explant and replacement. In other cases of temporary and/or partialimplantation (for instance, a catheter temporarily implanted in order toaccess a location within a patient), an electrode failure can requirethe device to be removed and replaced with another device in order toperform the intended procedure. This can lead to increased proceduretime, patient risk, and cost due to having to use multiple devices forone procedure. In this way, in some examples, the present subject matterincreases the robustness of the electrode 1040 and, in turn, increasesreliability of the ultimate device with which the electrode 1040 isbeing used.

Although the coupling tube 1050 is presently described as being usedwith the T-shaped electrode 1040, in other examples, it is contemplatedthat the coupling tube 1050 can be used with an electrode having a shapeother than a T-shape, such as, but not limited to, the examples of theelectrodes 140, 240, 340A, 340B, 340C, 540, 640, 740, 840, 940 describedherein. As such, electrodes of other shapes can benefit from theinclusion of a coupling tube by reducing, if not eliminating welds toreduce, if not eliminate, the adverse effects of HAZ within theelectrodes to thereby facilitate a more robust electrode in a finishedmedical device.

Referring to FIGS. 11A and 11B, in some examples, as described herein,the presently-described subject matter can be used in a medical device1100. That is, one or more electrodes 1140 can be disposed within themedical device 1100, the medical device 1100 being configured for atleast partial implantation within a patient. Although the medical device1100 of FIGS. 11A and 11B includes one electrode 1140, this is merelyillustrative. In various examples, the medical device 1100 can includemore than one electrode 1140 depending upon the application for whichthe medical device 1100 is to be used. In some examples, the electrode1140 is formed from a conductive tube 1130 in a manner similar to thatdescribed above with respect to the electrode 1040. In some examples,the electrode 1140 can include a coupling tube similar to the couplingtube 1050 described above. In other examples, the electrode 1140 caninclude no coupling tube and instead have direct coupling between aconductor wire 1110 and the conductive tube 1130.

In various examples, the elongate medical device 1100 can include apaddle lead, a cuff lead, or the like. In some examples, the medicaldevice 1100 includes a body 1102 at least partially surrounding the oneor more electrodes 1140. In some examples, the body 1102 is formed, atleast in part, from silicone. In other examples, the body 1102 can beformed from one or more other biocompatible materials.

In some examples, the one or more electrodes 1140 are disposed proximatea distal end of the medical device 1100. In some examples, the one ormore electrodes 1140 are connected by one or more conductor wires 1110to a corresponding number of contacts at a proximal end of the medicaldevice 1100. The one or more contacts, in some examples, are configuredto electrically couple with another medical device (not shown), such as,for instance, a pulse generator, a medical monitor, a mapping device, orthe like, either implantable or external, to, in turn, electricallycouple the one or more electrodes 1140 to the pulse generator, a medicalmonitor, a mapping device, etc. and enable the one or more electrodes1140 to stimulate tissue (including one or more of muscle tissue,nervous tissue, epithelial tissue, and/or connective tissue) of apatient and/or sense a physiological signal or condition of the patient.

In some examples, the one or more electrodes 1140 are each disposedwithin the medical device 1100 with at least an electrode surface 1144being exposed to an exterior of the medical device 1100. In someexamples, the electrode surface 1144 of each of the one or moreelectrodes 1140 is a substantially flat surface 1144 configured tocontact and stimulate tissue of a patient and/or sense a physiologicalsignal or condition. In various examples, the one or more electrodes1140 can be similarly shaped to one or more of the examples ofelectrodes described above, such as, but not limited the electrodes 140,440, 640, 840, 940, 1040. In other examples, the one or more electrodes1140 can have substantially flat surfaces 1144 differently shaped fromthose of the electrodes 140, 440, 640, 840, 940, 1040, provided themedical device 1100 is capable of properly functioning for theapplication for which the medical device 1100 is being used. In stillother examples, the one or more electrodes 1140 can have roundedsurfaces shaped similarly to those of the electrodes 240, 340, 540.

In some examples and with reference to FIGS. 1-11B, the present subjectmatter includes a method of forming a component 100, 200, 300A, 300B,300C, 400, 500, 600, 1000 or an assembly 300, 900 for a medical device700, 800, 1100. In some examples, a connection portion 114, 214, 314A,314B, 314C, 514 of a conductor wire 110, 210, 310A, 310B, 310C, 410,510, 610, 710, 810, 910, 1010, 1110 is operably coupled to a conductivetube 130, 230, 330A, 330B, 330C, 430, 530, 630, 1030, 1130. In someexamples, the connection portion 114, 214, 314A, 314B, 314C, 514 of theconductor wire 110, 210, 310A, 310B, 310C, 410, 510, 610, 710, 810, 910,1010, 1110 is placed in contact with the conductive tube 130, 230, 330A,330B, 330C, 430, 530, 630, 1030, 1130. In some examples, the connectionportion 114, 214, 314A, 314B, 314C, 514 of the conductor wire 110, 210,310A, 310B, 310C, 410, 510, 610, 710, 810, 910, 1110 is placed in directcontact with the conductive tube 130, 230, 330A, 330B, 330C, 430, 530,630, 1130. In other examples, the connection portion 114, 214, 314A,314B, 314C, 514 of the conductor wire 110, 210, 310A, 310B, 310C, 410,510, 610, 710, 810, 910, 1010, 1110 is placed in direct contact with acoupling tube 1050 in contact with the conductive tube 130, 230, 330A,330B, 330C, 430, 530, 630, 1030, 1130. In some examples, the conductorwire 110, 210, 310A, 310B, 310C, 410, 610, 710, 810, 910, 1010, 1110 isplaced in contact with an inner surface 134, 434, 634, 1034 of theconductive tube 130, 230, 330A, 330B, 330C, 430, 630, 1030, 1130. Inother examples, the conductor wire 510, 710, 810 is placed in contactwith an outer surface 536 of the conductive tube 530.

In some examples, an electrode 140, 240, 340A, 340B, 340C, 440, 540,640, 740, 840, 940, 1040, 1140 is formed by compressing the conductivetube 130, 230, 330A, 330B, 330C, 430, 530, 630, 1030, 1130 at leastpartially around the connection portion 114, 214, 314A, 314B, 314C, 514of the conductor wire 110, 210, 310A, 310B, 310C, 410, 510, 610, 710,810, 910, 1010, 1110 to at least partially surround and couple to theconnection portion 114, 214, 314A, 314B, 314C, 514. In some examples,the connection portion 114, 214, 314A, 314B, 314C, 514 of the conductorwire 110, 210, 310A, 310B, 310C, 410, 510, 610, 710, 810, 910, 1010,1110 is welded to the electrode 140, 240, 340A, 340B, 340C, 440, 540,640, 740, 840, 940, 1040, 1140. In some further examples, the connectionportion 114, 214, 314A, 314B, 314C, 514 is laser welding to theelectrode 140, 240, 340A, 340B, 340C, 440, 540, 640, 740, 840, 940,1040, 1140. In other examples, the connection portion 114, 214, 314A,314B, 314C, 514 is resistance welded to the electrode 140, 240, 340A,340B, 340C, 440, 540, 640, 740, 840, 940, 1040, 1140. In other examples,the connection portion 114, 214, 314A, 314B, 314C, 514 is mechanicallycoupled to the electrode 140, 240, 340A, 340B, 340C, 440, 540, 640, 740,840, 940, 1040, 1140 with the compression of the conductive tube 130,230, 330A, 330B, 330C, 430, 530, 630, 1030, 1130 at least partiallyaround the connection portion 114, 214, 314A, 314B, 314C, 514 of theconductor wire 110, 210, 310A, 310B, 310C, 410, 510, 610, 710, 810, 910,1010, 1110. In further examples, the compressing of the conductive tube130, 230, 330A, 330B, 330C, 430, 530, 630, 1030, 1130 around theconnection portion 114, 214, 314A, 314B, 314C, 514 also electricallycouples the connection portion 114, 214, 314A, 314B, 314C, 514 of theconductor wire 110, 210, 310A, 310B, 310C, 410, 510, 610, 710, 810, 910,1010, 1110 to the conductive tube 130, 230, 330A, 330B, 330C, 430, 530,630, 1030, 1130. In this way, in some examples, the connector portion114, 214, 314A, 314B, 314C, 514 of the conductor wire 110, 210, 310A,310B, 310C, 410, 510, 610, 710, 810, 910, 1010, 1110 is mechanically andelectrically coupled to the conductive tube 130, 230, 330A, 330B, 330C,430, 530, 630, 1030, 1130.

In some examples, the electrode 140, 240, 340A, 340B, 340C, 440, 540,640, 740, 840, 940, 1040, 1140 is formed by compressing the conductivetube 130, 230, 330A, 330B, 330C, 430, 530, 630, 1030, 1130 at leastpartially around the coupling tube 1050, within which is disposed theconnection portion 114, 214, 314A, 314B, 314C, 514 of the conductor wire110, 210, 310A, 310B, 310C, 410, 510, 610, 710, 810, 910, 1010, 1110, toat least partially surround and couple to the coupling tube 1050 and, inturn, the connection portion 114, 214, 314A, 314B, 314C, 514. In someexamples, the electrode 140, 240, 340A, 340B, 340C, 440, 540, 640, 740,840, 940, 1040, 1140 is formed by compressing the conductive tube 130,230, 330A, 330B, 330C, 430, 530, 630, 1030, 1130 into direct contactwith a coupling tube 1050, the conductor wire 110, 210, 310A, 310B,310C, 410, 510, 610, 710, 810, 910, 1010, 1110 being at least partiallydisposed within the coupling tube 1050. In some examples, the conductorwire 110, 210, 310A, 310B, 310C, 410, 510, 610, 710, 810, 910, 1010,1110 is coupled to the coupling tube 1050. In further examples, theconductor wire 110, 210, 310A, 310B, 310C, 410, 510, 610, 710, 810, 910,1010, 1110 is welded to the coupling tube 1050. In some examples, theconductor wire 110, 210, 310A, 310B, 310C, 410, 510, 610, 710, 810, 910,1010, 1110 is laser welded to the coupling tube 1050. In other examples,the conductor wire 110, 210, 310A, 310B, 310C, 410, 510, 610, 710, 810,910, 1010, 1110 is resistance welded to the coupling tube 1050.

In some examples, the electrode 140, 240, 340A, 340B, 340C, 440, 540,640, 740, 840, 940, 1040, 1140 is formed by compressing the conductivetube 130, 230, 330A, 330B, 330C, 430, 530, 630, 1030, 1130 at leastpartially around the connection portion 114, 214, 314A, 314B, 314C, 514of the conductor wire 110, 210, 310A, 310B, 310C, 410, 510, 610, 710,810, 910, 1010, 1110 to constrain motion of the connection portion 114,214, 314A, 314B, 314C, 514 of the conductor wire 110, 210, 310A, 310B,310C, 410, 510, 610, 710, 810, 910, 1010, 1110 relative to theconductive tube 130, 230, 330A, 330B, 330C, 430, 530, 630, 1030, 1130.

In some examples, the conductive tube 130, 230, 330A, 330B, 330C, 430,530, 630, 1030, 1130 includes an inner surface 134, 434, 534, 634, 1034facing inwardly toward an axis 132, 1032 of the conductive tube 130,230, 330A, 330B, 330C, 430, 530, 630, 1030, 1130 and an outer surface136, 436, 536, 636, 1036 facing outwardly away from the axis 132, 1032of the conductive tube 130, 230, 330A, 330B, 330C, 430, 530, 630, 1030,1130. In some examples, the connection portion 114, 214, 314A, 314B,314C of the conductor wire 110, 210, 310A, 310B, 310C, 410, 610, 710,810, 910, 1010, 1110 is coupled to a first portion 134A, 434A, 634A,1034A of the inner surface 134, 434, 634, 1034. Compressing theconductive tube 130, 230, 330A, 330B, 330C, 430, 530, 630, 1030, 1130,in some examples, causes the at least the first portion 134A, 434A,634A, 1034A of the inner surface 134, 434, 634, 1034 and the connectionportion 114, 214, 314A, 314B, 314C of the conductor wire 110, 210, 310A,310B, 310C, 410, 610, 710, 810, 910, 1010, 1110 to contact at least asecond portion 134B, 434B, 634B, 1034B of the inner surface 134, 434,634, 1034 to substantially sandwich the connection portion 114, 214,314A, 314B, 314C of the conductor wire between the first portion 134A,434A, 634A, 1034A of the inner surface 134, 434, 634, 1034 and thesecond portion 134B, 434B, 634B, 1034B of the inner surface 134, 434,634, 1034. In some examples, the connection portion 514 of the conductorwire 510 is coupled to a first portion 536A of the outer surface 536 andthe conductive tube 530 is compressed such that the first portion 536Aof the outer surface 536 wraps at least partially around the connectionportion 514 of the conductor wire 510 to form a channel within which theconnection portion 514 of the conductor wire 510 can be disposed. Inother examples, the conductive tube 130, 230, 330A, 330B, 330C, 430,530, 630, 1030, 1130 or the electrode 740, 840, 940 is compressed aroundand coupled to the coupling tube 1050, which, in turn, is coupled to theconnection portion 114, 214, 314A, 314B, 314C, 514 of the conductor wire110, 210, 310A, 310B, 310C, 410, 510, 610, 710, 810, 910, 1010, 1110. Insome examples, an axial extent of the conductive tube 130, 230, 330A,330B, 330C, 430, 530, 630, 1030, 1130, the electrode 740, 840, 940,and/or the coupling tube 1050 is deformed to contact itself, sandwichingthe connector portion 114, 214, 314A, 314B, 314C, 514 of the conductorwire 110, 210, 310A, 310B, 310C, 410, 510, 610, 710, 810, 910, 1010,1110 in between. That is, from a first edge (such as a proximal edge) toa second edge (such as a distal edge), the conductive tube 130, 230,330A, 330B, 330C, 430, 530, 630, 1030, 1130 is deformed so that spacedapart portions of the first edge are compressed together to contact eachother, spaced apart portions of the second edge are compressed togetherto contact each other, and spaced apart portions disposed axially inbetween the first edge and the second edge are compressed together tocontact each other.

In some examples, the electrode 140, 240, 340A, 340B, 340C, 740, 840 isformed by compressing the conductive tube 130, 230, 330A, 330B, 330Csuch that the electrode 140, 240, 340A, 340B, 340C, 740, 840 formed issubstantially U-shaped. In other examples, the electrode 440, 840, 940,1040, 1140 is formed by compressing the conductive tube 430, 1030, 1130such that the electrode 440, 840, 940, 1040, 1140 formed issubstantially T-shaped. In still other examples, the electrode 540, 640is formed into other shapes, such as substantially flattened,substantially ring-shaped, or the like. In some examples, the electrode140, 240, 340A, 340B, 340C, 440, 540, 640, 740, 840, 940, 1140 is formedby compressing the conductive tube 130, 230, 330A, 330B, 330C, 430, 530,630, 1130 into direct contact with the conductor wire 110, 210, 310A,310B, 310C, 410, 510, 610, 710, 810, 910, 1110.

In various examples, the conductive tube 130, 230, 330A, 330B, 330C,430, 530, 630, 1030, 1130 and/or the electrode 740, 840, 940, can beformed from or otherwise include one or of platinum; a platinum alloy,such as, but not limited to, a platinum-iridium alloy; gold; a goldalloy; a nickel-cobalt alloy, such as, but not limited to, MP35N;stainless steel; and/or other biocompatible materials capable ofconducting electrical signals. In various examples, the coupling tube1050 can be formed from or otherwise include one or of platinum; aplatinum alloy, such as, but not limited to, a platinum-iridium alloy;gold; a gold alloy; a nickel-cobalt alloy, such as, but not limited to,MP35N; stainless steel; and/or other biocompatible materials capable ofconducting electrical signals. In some examples, the coupling tube 1050can be formed from the same one or more materials as the conductive tube130, 230, 330A, 330B, 330C, 430, 530, 630, 1030, 1130 and/or theelectrode 740, 840, 940. In other examples, the coupling tube 1050 canbe formed from the one or more materials that are different from the oneor more material of the conductive tube 130, 230, 330A, 330B, 330C, 430,530, 630, 1030, 1130 and/or the electrode 740, 840, 940. In variousexamples, the conductor wire 110, 210, 310A, 310B, 310C, 410, 510, 610,710, 810, 910, 1010, 1110 can be formed from or otherwise include one orof nickel; a nickel-cobalt alloy, such as, but not limited to, MP35Nand/or a drawn tube including a MP35N tube with a silver core; platinum;a platinum alloy, such as, but not limited to, a platinum-iridium alloy;stainless steel; and/or other biocompatible materials capable ofconducting electrical signals.

The present inventors have recognized various advantages of the subjectmatter described herein. The present inventors have recognized, amongother things, that the present subject matter can be used in a device toconnect a conductor wire to an electrode. Such a device includes, but isnot limited to, a medical device. In various examples, the presentsubject matter is advantageous in that it provides for a connectionbetween the conductor wire and the electrode in a manner that caninhibit premature breakage of the conductor wire or breakage of theconductor wire from the electrode. In some examples, the present subjectmatter inhibits breakage of the conductor wire and/or the connectionbetween the conductor wire and the electrode within the HAZ. Whilevarious advantages of the example systems are listed herein, this listis not considered to be complete, as further advantages may becomeapparent from the description and figures presented herein.

Although the subject matter of the present patent application has beendescribed with reference to various examples, workers skilled in the artwill recognize that changes can be made in form and detail withoutdeparting from the scope of the subject matter recited in the belowclaims.

The above Detailed Description includes references to the accompanyingdrawings, which form a part of the Detailed Description. The drawingsshow, by way of illustration, specific examples in which the presentapparatuses and methods can be practiced. These embodiments are alsoreferred to herein as “examples.”

The above Detailed Description is intended to be illustrative, and notrestrictive. For example, the above-described examples (or one or moreelements thereof) can be used in combination with each other. Otherembodiments can be used, such as by one of ordinary skill in the artupon reviewing the above description. Also, various features or elementscan be grouped together to streamline the disclosure. This should not beinterpreted as intending that an unclaimed disclosed feature isessential to any claim. Rather, inventive subject matter can lie in lessthan all features of a particular disclosed embodiment. Thus, thefollowing claims are hereby incorporated into the Detailed Description,with each claim standing on its own as a separate embodiment. The scopeof the invention should be determined with reference to the appendedclaims, along with the full scope of equivalents to which such claimsare entitled.

In this document, the terms “a” or “an” are used to include one or morethan one, independent of any other instances or usages of “at least one”or “one or more.” In this document, the term “or” is used to refer to anonexclusive or, such that “A or B” includes “A but not B,” “B but notA,” and “A and B,” unless otherwise indicated. In this document, theterms “about” and “approximately” or similar are used to refer to anamount that is nearly, almost, or in the vicinity of being equal to astated amount.

In the appended claims, the terms “including” and “in which” are used asthe plain-English equivalents of the respective terms “comprising” and“wherein.” Also, in the following claims, the terms “including” and“comprising” are open-ended, that is, an apparatus or method thatincludes elements in addition to those listed after such a term in aclaim are still deemed to fall within the scope of that claim. Moreover,in the following claims, the terms “first,” “second,” and “third,” etc.are used merely as labels, and are not intended to impose numericalrequirements on their objects.

The Abstract is provided to allow the reader to quickly ascertain thenature of the technical disclosure. It is submitted with theunderstanding that it will not be used to interpret or limit the scopeor meaning of the claims.

The invention claimed is:
 1. A method of making a component for amedical device, the method including: electrically coupling a connectionportion of a conductor wire to a conductive tube; and forming anelectrode by compressing the conductive tube at least partially aroundthe connection portion of the conductor wire to at least partiallysurround and couple to the connection portion, wherein forming theelectrode includes: forming a flattened portion of the conductive tubeto form a substantially flat surface configured to contact and stimulatetissue; and forming a leg from the conductive tube, the leg extendingsubstantially perpendicularly from the flattened portion of theelectrode, the flattened portion and the leg forming a T-shape, whereinthe connection portion of the conductor wire is disposed within the legof the electrode.
 2. The method of claim 1, wherein electricallycoupling the connection portion of the conductor wire to the conductivetube includes placing the connection portion of the conductor wire indirect contact with the conductive tube.
 3. The method of claim 1,wherein electrically coupling the connection portion of the conductorwire to the conductive tube includes placing the connection portion ofthe conductor wire in direct contact with a coupling tube in contactwith the conductive tube.
 4. The method of claim 3, comprising weldingthe connection portion of the conductor wire to the coupling tube. 5.The method of claim 3, wherein forming the electrode includescompressing the conductive tube at least partially around the couplingtube to at least partially surround and couple the electrode to thecoupling tube and the connection portion of the conductor wire.
 6. Themethod of claim 5, comprising welding the coupling tube to theelectrode.
 7. The method of claim 1, comprising welding the connectionportion of the conductor wire to the electrode.
 8. The method of claim1, wherein forming the electrode includes mechanically coupling theconnection portion to the electrode with compression of the conductivetube at least partially around the connection portion of the conductorwire.
 9. The method of claim 1, wherein forming the electrode includesforming the leg such that the connection portion of the conductor wireis disposed at an end of the leg of the electrode spaced farthest awayfrom the flattened portion of the electrode.
 10. The method of claim 1,wherein forming the electrode includes forming the leg such that the legof the electrode extends substantially perpendicularly from a center ofthe flattened portion of the electrode.
 11. A method of making acomponent for a medical device, the method including: electricallycoupling a connection portion of a conductor wire to a conductive tube,the conductive tube including an inner surface facing inwardly toward anaxis of the conductive tube and an outer surface facing outwardly awayfrom the axis of the conductive tube, the connection portion of theconductor wire being coupled to a first portion of the inner surface;and forming an electrode by collapsing the conductive tube such that atleast the first portion of the inner surface and the connection portionof the conductor wire contacts at least a second portion of the innersurface to substantially sandwich the connection portion of theconductor wire between the first portion of the inner surface and thesecond portion of the inner surface, wherein forming the electrodeincludes: forming a flattened portion of the conductive tube to form asubstantially flat surface configured to contact and stimulate tissue;and forming a leg from the conductive tube, the leg extendingsubstantially perpendicularly from the flattened portion of theelectrode, the flattened portion and the leg forming a T-shape, whereinthe connection portion of the conductor wire is disposed within the legof the electrode.
 12. The method of claim 11, wherein electricallycoupling the connection portion of the conductor wire to the conductivetube includes placing the connection portion of the conductor wire indirect contact with the conductive tube.
 13. The method of claim 11,wherein electrically coupling the connection portion of the conductorwire to the conductive tube includes placing the connection portion ofthe conductor wire in direct contact with a coupling tube in contactwith the conductive tube.
 14. The method of claim 13, comprising weldingthe connection portion of the conductor wire to the coupling tube. 15.The method of claim 13, wherein forming the electrode includescollapsing the conductive tube at least partially around the couplingtube to at least partially surround and couple the electrode to thecoupling tube and the connection portion of the conductor wire.
 16. Themethod of claim 15, comprising welding the coupling tube to theelectrode.
 17. The method of claim 11, comprising welding the connectionportion of the conductor wire to the electrode.
 18. The method of claim11, wherein forming the electrode includes mechanically coupling theconnection portion to the electrode with collapsing of the conductivetube at least partially around the connection portion of the conductorwire.
 19. The method of claim 11, wherein forming the electrode includesforming the leg such that the connection portion of the conductor wireis disposed at an end of the leg of the electrode spaced farthest awayfrom the flattened portion of the electrode.
 20. The method of claim 11,wherein forming the electrode includes forming the leg such that the legof the electrode extends substantially perpendicularly from a center ofthe flattened portion of the electrode.